Automatic temperature control for injection molding machines



June 6, 1944.1 G. SMITH 2,350,539

AUTOMATIC TEMPERATURE CONTROL FOR INJECTION MOLDING MACHINES y i y ya, j@ fz@ y June 6, 1944. SMITH 2,356,539

AUTOMATIC TEMPERATURE CONTROL FOR INJECTION MOLDING MACHINES Filed March 14, 1940 2 Sheets-Sheet 2 Patented June 6, 1944 AUTOMATIC TEMPERATURE CONTBGL FOR INJECTION HOLDING MACHINES Graydon Smith, Cambridge, Masa., assigner to Reed-Prentbe Corporation, Worcester, Mall., a

corporation of Massachusetts Application March 14, 1940, Serial No. 323,871

a claim. (ci. is-se) The present invention relates to injection molding machines, particularly those employing material which is first rendered plastic by the application oi heat, and is then injected into cooperating dies under pressure. .a

Injection molding machines of the above indica ted character normally operate in accordance with a uniform cycle involving the feeding, plasticizing and injection of predetermined amounts of thermoplastic or thermosetting materials for each complete cycle. Since material of this character usuallyexhibits a relatively narrow temperature range in which it has the desired i'iow or setting characteristics, it has heretofore been proposed to obtain heating of the material at a constant temperature, such as to insure the ready flow of the same through the heating apparatus and its injection into the dies at a temperature best suited for the molding operation. However, diiliculties have arisen whenever the timing of the normal operating cycle of the machine is upset for any reason. due to the fact that the degree of heat purposely maintained for a given material may well become such as to cause burning or premature setting of the material, should the operating cycle be slowed down appreciably, or to cause incomplete plasticization should the operating cycle be speeded up.

The object of the present invention is to `provide an improved automatic temperature control apparatus for injection molding machines, functioning in such a manner as to effectively prevent overheating or underheating of the material being plasticized, in the event of any occurrence tending to upset the timing of the normal cycle of operation of the machine. Briefly stated, the invention contemplates the utilization of control apparatus directly responsive to successive operations oi the machine, whereby any slowing down or speeding up of the normal operating cycle will be automatically followed by a lowering or raising of the temperature to which the material is subjected in the plasticizing zone, until such time as the normal operating cycle is resumed.

The above and other advantageous features of the invention will hereinafter more fully appear from the following description, considered in connection with the accompanying drawings, in which:

Fig. 1 is a diagrammatic view, illustrating the control apparatus as applied to an injection molding machine. v

Fig. 2 is a view in front elevation, showing the 66 external appearance of a control box containing the apparatus of Fig. l. f

Pig. 3 is a fragmentary view, illustrating a modiilcation of the control apparatus.

Fig. 4 is a wiring diagram illustrating the functioning of the apparatus shown in Fig. 4.

Fig. 5 is a schematic view, illustrating the invention as applied to multiple temperature control at diiferent parts of a machine.

Referring to Fig. 1, a portion of an injection molding machine is shown digrammatically as comprising a heating and injection cylinder i, to which suitable heat plasticizable material is fed from a hopper 2 for injection into suitable dies 3, under the pressure developed within the cylinder I by a plunger l. Reciprocatory movement is adapted to be imparted to the injection plunger l by means of a piston l operating in a cylinder 6, with suitable iiuid pressure controlled means l, indicated as a valve device, being provided to cause successive reciprocations of the injection plunger I, in accordance with a predetermined timing.

Material fed to the cylinder I is adapted to be plasticized therein by the heat generated through enersization of a coil l from a suitable source of electrical energy represented by the supply mains l. One terminal oi' the coil I is connected to one supply main l, while the other terminal thereof is adapte? to be intermittently connected to the other supp vmain through relatively movable contacts Il, forming part of a potentiometer controller Ii. T'he injection cylinder l also provides a thermocouple I2, the terminals of which are connected by conductors |2a to the potentiometer ii, as well as to a control panel I I. the function of which will hereinafter appear.

The potentiometer II is of any well known type commercially available, and need not be described in detail herein, other than to state that the potentiometer is adapted to control, through its contacts III, the connection or disconnection of the coil l to the mains 9. Such control is normally dependent upon the functioning of the potentiometer Il, in response to voltage generated by the thermocouple I2, when the temperature within the injection cylinder reaches a predetermined degree, the net result being that the coil l is energized and deenergized at intervalsto maintain a constant temperature within the injection cylinder i, best suited for the plasticization and injection of the particular material being utilized by the machine.

The parts of the injection molding machine described thus far form no part of the present invention per se, and are more fully shown and described in my co-pending application, Serial No. 259,404, led jointly with Edward S. Bird and Leon F. Marsh,.on March 2, 1939. It is to be understood that the arrangement and functioning of the machine parts described above are merely illustrative of the manner in which an injectionA molding machine may be operated, while maintaining the injection cylinder at a constant temperature, and that the invention about to be delV scribed may be applied to other types of injection molding machines equipped with otherA types of heating devices and temperature control.

In normal operation of the machine described above, the potentiometer II is given a setting, by

.means of the control lmob I Ia. such, for example, as will maintain the injection cylinder I at a temperature of approximately 400. This particular temperature is chosen to meet the thermal characteristics of the material being molded, and is also chosen on the assumption that the machine will operate with a uniform cycle, such as will insure, for example, 60-second intervals between injection shots. Therefore, the normal and expected functioning of the thermocouple I2 in con- 25 junction with its potentiometer Il, is such as to insure that the coil 8 for generating the heat will be disconnected while the temperature within the cylinder I remains substantially at 400.

Let it now be assumed that after the machine has been operating over an appreciable period with a given timing and potentiometer setting.

such as indicated above, somethingA happens to upset the timing of the operating cycle. Thisv might readily'occur, should the machine operator 35 purposely increase the intervals between injection shots to make adjustments in the dies, or perform some other operation not contemplated when the potentiometer I0 was originally set to maintain a 400 temperature within the cylinder vI, on the 40 basis of a 60-second operating cycle. When such an increase in the length of the operating cycle occurs, such as might extend the average interval between shots to 90v seconds, it is evident that the thermocouple I2 and the potentiometer Il will 45 continue to function as before, to maintain a constant temperature of 400, within the heating cylinder. Moreover, should the increased time interval between shots be sustained for any considerable number of cycles, it is evident that the material within th cylinder I will become overplasticized and possibly burned, or even set, in cases where a thermosetting material is being handled, due to the material being subjected to a predetermined temperature for longer periods than was originally contemplated, when the potentiometer II was set.

In order to prevent such over-heating, or setting, of the material being handled, the present invention contemplates the provision of an automatic temperature control means to bring about a reduction of the temperature` within the cylinder I immediately upon the occurrence of any appreciable increase in the time interval between successive injection shots of the plasticized material.

To this end, the previously mentioned control panel I3 provides a vacuum tube Il, shown as being of the three-electrode thermionic valve type. The anode I5 of this tube I4 is connected to a suitable direct current voltage source I6.

condenser 20, having a variable resistor 2| connected across its terminals. A conductor 22-lead ing from a point between the grid I 0 and one condenser terminal, is adapted to charge the con denser 20 from the negative side of the source II through closure of the contacts 23.01.' a relay. which contacts are normally open. The winding 24 of this relay'has one terminal connected to one supply main 9, while its otherV terminal is connected to one of a pair of relatively movable contacts 25 oi a timing device. The other contact of this device is connected to the other supply main 9, and normally separated from the first contact. The timing device is of any suitable character, and as shown herein, consists of an actuator or cam element 26. movable with the pistonrod 5a, so that the contacts 25 are momentarily closed as the injection plunger 4 nears'the end of its injection stroke, to force plasticized material from the cylinder I into the dies 3.

Closure of the contacts 25 of the timingdevice will energize the relay winding to bring about a momentary closure of the contacts 23, therebyv i imparting a negative charge to the grid condenser 20, after which the contacts 23 open. As long as the condenser 20 retains an appreciable negative charge, current flowing through the tube I4 to the anode I5 will be negligible, and will approach zero, although the negative condenser charge will tend to leak away through the variable resistor 2|, at a rate determined by the settirg of this resistor.

Let it now be assumed that the machine, with a given potentiometer setting of, say, 400 for the injection cylinder I, is operating with a selected time interval of 60 seconds between shots. As the injection plunger 4 moves back and forth, it is evident that once during each cycle, as the plunger l nears the end of its injection stroke, the grid condenser 20 will receive a negative charge, as a result of the momentary closure of relay contacts 23. The capacity of the condenser 20 and the setting of the grid resistor 2| are such that when the machine is operating normally on a xed cycle, with regular intervals between injection shots, the condenser 2li is charged frequently enough to maintain suiilcient negative bias on the grid I9 to reduce the anode current substantially to zero. Therefore, the voltage impressed on the potentiometer I I remains substantially that generated by the thermocouple I2, and the temperature within the injection cylinder I remains substantially constant, in accordance with the setting of the potentiometer. In other words, as long as the timing of the cycle remains uniform, that portion of the resistor I8 included in the potentiometer circuit, has no appreciable influence on temperature control.

grid condenser 20 will receive successive charges at much longer intervals than before. Consequently, the negative current charge will have time to leak away to such an extent as to cause an immediate increase in the current flowing to the anode I5. As a result of this current flowing through a portion of the resistor I8, a voltage will be imposed upon the potentiometer in addition to the voltage of the thermocouple I2, and current will be cut oi from the heating coil 8 when this voltage reaches that particular value at which the thermocouple voltage has heretofore been eiective. 'I'he net result of the above described functioning of the tube Il is that even with a potentiometer setting of 400, the injection cylinder I will be actually maintained at a temperature appreciably less than 400, thereby preventing over-plasticizing and burning of the material, or setting of the material within the cylinder, when employing material of the thermosetting type.

Should the normal timing for the operating cycle of the machine be resumed, the decreased intervals between successive charges on the condenser 20 will quickly lessen its previous rate of discharge, so that the negative bias on the grid I9 will again be suflicient torestrict the flow of current to the anode I5, to such a low value that the functioning of the potentiometer II will not be affected by conditions in the tube circuit.

Referring now to Fig. 2, there is shown the external appearance of a control box containing the apparatus, previously described as being mounted on the control panel I3. The front 21 of the control box provides a turnable knob 28 for operating the movable arm I8a of the variable resistor I8 and a pointer 29 carried by the knob 28 cooperates with a series of scale markings 30 calibrated to indicate the temperature that will be maintained in the heating cylinder I for any given setting of the resistor I8. That is to say, the scale markings 30 will be in inverse ratio to the portions of the resistor I8 that are included in circuit with the thermocouple, so that with a potentiometer setting for 400, for example, a setting of the pointer 23 at 300 will indicate the maximum temperature reduction that will be elfected through functioning of the tube I4, should the operating cycle be interrupted completely.

In order to indicate the actual temperature drop that is effective at any given moment during the functioning of the control apparatus, a milliameter 3| is connected in circuit with the resistor I8, and the movable pointer 32 of this instrument is visible from the front of the control box, as indicated. The pointer 32 cooperates with scale markings 33, calibrated directly in terms of temperature drop. Since the current flowing through the milliameter 3| is a direct measure of the voltage drop across that portion of the resistor I8 included in circuit with the thermocouple I2, it follows that the pointer 32 will indicate the actual reduction in temperature that is effective at any time.

As previously indicated, the resistor 2I through which the condenser 20 discharges is variable, and a knob 3| controlling this resistor provides a pointer 35 cooperating with scale markings 33, calibrated in terms of time delay. Since the setting of the resistor 2| controls the rate of discharge of the condenser 20, the scale markings 35 are in direct proportion to the amount of the resistor 2| that is connected across the terminals of the condenser 20 for any given setting of the knb 35. For example, with the knob 34 set to include only a small portion of the resistor 2| in circuit, the rate of discharge of the condenser 20 willbe at a maximum, and the pointer 35 will indicate that the tube Il will function to pass current sufficient to lower the temperature of the heating cylinder I, upon the occurrence of a relatively slight delay in the timing of the operating cycle, such as V4 of a minute. With the entire resistor 2| connected across the condenser terminals, the rate of discharge can be so reduced as to require a delay of as much as three or five minutes before the tube II- became effective, as indicated by the scale markings 33.

The specific figures given above with reference to the scale markings 38 and 35, for given settings of the variable resistors I3 and 2|, are purely illustrative of the manner in which the control apparatus embodying the present invention can be utilized to meet specific temperature requirements of the material being handled. Obviously, there will be a very wide range of temperature requirements, each requiring a different setting of the control knobs 28 and 34, when handling thermoplastic materials having different temperature ranges. Furthermore, the amount of regulation required will depend a great deal on the length of the operating cycle for any given material, and it has been found that the resistors I8 and 2| can be set to meet any operating condition, both as regards temperature range and duration of cycle.

While the specific figures given above are illustrative of the manner in which the temperature is automatically reduced upon slowing down of the operating cycle, the apparatus is equally capable of being initially set so as to automatically bring about an increase of temperature should the operating cycle be speeded up and thereby increase the rate at which the material is used. For example, let it be assumed that the discharging resistor 2| for the condenser 20 is initially set at auch a low value that even with a normal operating cycle of 60 seconds, the grid charge will leak ofi' so rapidly that the tube will normally pass some current. Therefore, there will be a more or less constant voltage impressed on the potentiometer in addition to the voltage of the thermocouple I2, so that the temperature which is automatically maintained, say with a setting of 400, is a function of the combined voltages so long as the timing of the operating cycle of the machine remains constant.

If it now be assumed that the operating cycle of the machine is speeded up, so as to reduce the intervals between injection shots from 60 seconds to 45 seconds, for example, then the condenser will be charged more frequently. When this occurs, the intervals during which the negative grid charges can leak olf, become so short as to maintain sufficient negative bias on the grid, to reduce the anode current substantially to zero. When this occurs, the voltage impressed on the potentiometer, becomes substantially that generated by the thermccouple I2 alone, so that an increased temperature of as high as 450-500 will be automatically maintained within the injection cylinder, with a potentiometer setting of 400. This temperature rise thus compensates for the increased rate of use of the plasticized material as a result of the speeding up in the operatipn of the machine.

When utilizing the apparatus to automatically bring about either a decrease or increase in the temperature of the heating cylinder, it is only necessary to calibrate the temperature indicator of the potentiometer II, so that any given setting thereof presupposes the passage of sufiicient current by the tube Il, to maintain an initial potential in the potentiometer circuit, in addition to that of the thermocouple. Obviously. with such a calibration, it follows that the temperature of the heating cylinder will be automatically raised or lowered from any given setting, in response to a speeding up or slowing down of the operating cycle.

Referring now to Figs. 3 and 4, there is shown diagrammatically a modified arrangement for obpreviously described. In this modified arrangement, a control resistor 31 provides a number of taps 3l, that are adapted to be engaged by an arm 39 freely mounted on a shaft Il.` The arm 33 is also adapted to engage an arcuate conducting segment 3|, and the resistor 31 and the segment Il are included in a circuit energized from .a source 42, with the amount of current flowing through the resistor 31 being under the control of a variable resistor 33.

'I'he contact arm 33 is included in one side of the potentiometer circuit in series with the thermocouple |2,vbut with the arm 39 engaging the segment 3l, the amount of current that may be flowing through the resistor 31 has no ellect on the potentiometer circuit. However, should the arm 39 be turned to engage one of the taps 33, a voltage will be impressed on one side of the potentiometer circuit in addition to thevoltage generated by the thermocouple I2. This added voltage will depend on what portion of the resistor 31 is included between a given tap 33 and the segment Il, and the amount of current that is flowing through the controlling resistor 31 in accordance with the setting of the variable resistor I3.

The contact arm 33 tends to turn on shaft 40 under the pull of weight 33a, and provides an extension M carrying a restraining pawl 4l adapted to engage the teeth of a ratchet wheel 3i mounted to turn with the shaft Ii. 'I'he shaft 40 is adapted to be rotatably driven ata con-. stant predetermined speed, by any suitable means, such as an electric motor 31. so that turning of the ratchet wheel 43 with the shaft 33 will permit the pawl 35 to follow the wheel and thereby control turning movement of the arm 39 under the pull of the weight 33a. Such turning movement of the arm 33, if permitted to continue, will result in the arm 33 leaving the segment Il and successively engaging the taps 33 so as to impress increments of voltage on'one side of the potentiometer circuit, in addition to the voltage generated by the thermocouple I2.

Y 'I'he pawl 45.,.however, is adapted to be moved at intervals inditlonfoppsite to the move-4 ment of the teeth on the ratchet wheel 46, by means of a plunger I3 connected to the extension u, through suitable linkage 43a, with the plunger 43 being under the control of a solenoid` 49 that is adapted to be energized at intervals by the contacts 25 of the timing device shown in Fig. 1.

Assuming that the parts occupy the position of Fig. 3 at the start of a molding cycle, such as has been previously described. the pawl I5 will be free to follow the ratchet wheel 46 as the shaft 40 turns, thereby permitting the arm 33 to move along the segment 4I. Should the timing of the `operating cycle of the injection molding machine be such that the solenoid I3 will be energized before the arm 39 leaves the segment Il and engages the first tap 33, then it is apparent that vthe controlling resistor 31 will have no eiecton the potentiometer circuit and the thermocouple l2 will function to automatically maintain the material being plasticized at the particular temperature determined b the initial setting of the potentiometer.

If, however, the operating cycle of the machine be changed, so as to increase the length of the intervals between successive shots of plasticized material, then the arm 33 will be permitted to assess@ such an extent that the arm will engage one or more of the taps' 33 of the controlling resistor 31, before the next energization of the solenoid I3 returns the arm to its initial position in ensagement with the upper end of the segment Il. When this occurs, a voltage is impressed on the potentiometer circuit, in addition to the voltage this follow the movement of .the ratchet wheel to then generatedy by the thermocouple I2, which results in automatically deenergizing the heating coil 3 sooner than would have otherwise occurred, to thereby decrease the temperature to which the material is subjected.

Should the operating cycle of the 'machine be initially set, so that the arm 33 is permitted to engage one or more taps 38 before the pawl is retracted by energization of the solenoid 4l, then a predetermined voltage will be impressed on the potentiometer circuit, in addition to the thermocouple voltage during each cycle. Then should the .machine be speeded up so as to decrease the time intervals between shots, the more frequent energizations of the solenoid Il will prevent the ann 39- from a tap` 33. with a resulting decrease in the voltage in the potentiometer circuit, and an increase in the temperature to which the material is subjected.

Referring now to Fig. 5, there is shown, diagrammatically, the further application of the invention to automatically control the temperature at different portions of the heating cylinder I: In arrangement, separate potentiometers Ila and I Ib are employed to uniformly maintain different temperatures in the body and nose portions of the cylinder l, under the control of separate thermocouples Iza and I2b. Therefore, separate control panels l3a and I3b are employed, with'each panel connected in circuit with the corresponding thermocouple IIa or Hb. With the potentiometers lia and IIb set to maintain a xed temperature diii'erentiai between the body and nose portion of the cylinder I, it is evident that the apparatus on the separate control panels l3a and I3b will function independently. as described above with reference to Fig. l. to automatically bring about the desired temperature reduction, upon a change in the timing of the operating cycle,- in proportion to the initial temperature differential that may exist between different parts of the the heating cylinder. If desired, a third potentiometerv lic can be employed with electrically heated dies 3a, in cooperation with a thermocouple I2c and control panel I3c to reduce the die temperature when employing a thermosetting material.

From the foregoing, it is apparent that by the present invention there is provided an improved automatic temperature control for injection molding machines, functioning in such manner as to effectively prevent overheating and premature setting of the material being plasticized, or underheating of the material, in the event of any occurrence tending to upset the timing of the normal operating cycle of the machine. Stated another way, the apparatus of the present invention provides means for automatically controlling the degree of heat to which the material is subjected. directly in accordance with the rate of use of the plasticized material.

I claim:

1. In combination, die means, an injector said die means. thermostatically controlled means for heating plasticizable` chosen as best suited for the .and an electronic discharge regular intervals in accordance witna predetermined operating cycle, with the temperature at whichthe material is normally maintained being chosen as best suited for the length of said cycle, -`v-'and mechanism automatically responsive to any variations in the operating cycle of said injector for determining the temperature to which the plasticized material is actually subjected.

2. In combination, die means, an injector adapted to engage said die means, thermostatically controlled means for heating plasticizable material within said injector to a predetermined temperature, means for ejecting plasticized material from said injector into said die means at regular intervals in accordance with a predetermined operating cycle, with the temperature at which the material is normally maintained being chosen as best suited for he length of said cycle, and mechanism automatically reing machines, comprising in combination, a

sponsive to any increase in the intervals between which plasticized material is injected into said die means for decreasing the temperature to vhgl the plasticized materia1 is actually sub- 3. In combination, die means, .an injector adapted to engage said die means,-thermostat ic'ally controlled means for heating plasticizable material within said injector to a predetermined temperature, means for ejecting plasticized material from said injector into said die means at regular intervals in accordance with a predetermined operating which the material is normally maintained being chosen as best suited for the length of said cycle, and electro-responsive means synchronized with the-operating cycle of said injector for automatically determining the temperature to which the plasticized material is actually subjected.

4. In combination, die means, an injector adapted to engage said die means, thermostatically controlled means for heating plasticizable material within said injector to a predetermined temperature, means for eiecting plasticized material from said injector into said die means at regular intervals in accordance with a predetermined operating cycle, with the temperature at which the material is normally maintained being length of said cycle, device responsive to any variations in the operating cycle of said in- :lector for automatically determining the temperature to which the plasticized material is actually subjected.

5. Heat control apparatus for injection molding machines, comprising in combination, a member provided with thermostatically controlled means for heating plasticizable material therein to a predetermined temperature, means cycle, with the temperature at member provided with thermostatically oontrolled means for heating plasticizable material therein to. a predetermined temperature, means 4for ejecting plasticized material from said member at regular intervals, with said predetermined temperature of the material being chosen t0 obtain the desired degree of plasticity and in accordance with the length of intervals between successive elections of material, and vmeans for automatically reducing the temperature oi said member, in res'ponse to any increase in the intervals between which plasticized material is ejected therefrom.

7. Heat control apparatus for injection molding machines, comprising in combination, a member provided with thermostatically controlled means for heating plasticizable material therein to a predetermined temperature, means for ejecting plasticized material from said member at regular intervals, with said predetermined temperature of the material being chosen to obtain the desired degree of plasticity, and in accordance with the length of intervals between successive ejections of material, and means sup. plementing the operation of said thermostatically controlled heating means for additionallv controlling the temperature to which the material is subjected, in response to any alteration in the length of the intervals between successive elections of material from said member.

8. Heat control apparatus for injection molding machines, comprising in combination, a member provided with thermostatically controlled means for heating plasticizable material therein to a predetermined temperature, means for ej ecting plasticized material from said member at regular intervals, with said predetermined temperature of the material being chosen to obtain the desired degree of plasticity and in accordance with the length of intervals between successive ejections of material, and means supplementing the operation of said thermostatically controlled heating means for automatically reducing the temperature to which the material is subjected in said member, in response to any increase in the intervals between which plasticized material is ejected therefrom.

GRAYDON SMITH. 

